In pictures: inside the 'Force Awakens' stormtrooper dressing room

This article is a preview of WIRED magazine 01.16, our Star Wars special issue featuring J.J. Abrams, on sale from December 10 2015. Follow our Star Wars: The Force Awakens hub page for all of our web, print and behind-the-scenes coverage.

Even in galaxies far, far away you can't escape the influence of Jony Ive.

When costume designer Michael Kaplan (Blade Runner, Star Trek) was looking for a way to update the stormtroopers for The Force Awakens, his inspiration came partly from the phone in his pocket. "With time, I think, simplification occurs," says Kaplan."Because the stormtroopers are hard and white and plasticky, my thoughts did go to Apple."

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Where once were bumps and nodules, now are clean lines and floating faceplates.

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The revised stormtroopers are illustrative of Kaplan's general approach to the new film's approximately 1,500 costumes, which had to retain the spirit of the original films while also showing the passing of three decades, both in fictional and real-world technology. In the case of the stormtroopers, that meant a smoother silhouette but also construction more suited to battle than their 70s counterparts.

Stormtrooper helmet

Lucasfilm 2015

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"The original stormtroopers were vacuum-formed," says Kaplan. "That process required a much thinner plastic to be heated and molded. These are much harder [cast in polyurethane], so they don't crack. They're much tougher materials, plus they have more flexibility."

For the film's villain, the Vader-worshipping Kylo Ren, Kaplan had the job of evoking the past without directly copying it.

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"Kylo Ren feels a kinship with Darth Vader, so there is a bit of emulation," he says. Particularly in the mask, for which Abrams' specification was that Kaplan create, "something that would make a child want to see the movie".

The most striking costume revealed thus far was never originally supposed to be used. The elegant silver armour of Captain Phasma, a first order officer played by Gwendoline Christie, started as just a whim of Kaplan's.

Lucasfilm 2015

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"I loved the idea of taking a stormtrooper into the world of armour," he says. "It was just something I had in my head. The concept artist took my sketch and came up with a really beautiful illustration. I loved it and I hung it on the wall of our design room.

Kathy Kennedy came by and pointed at it and exclaimed, 'That is fantastic.' JJ loved it as well, so he created the role of Captain Phasma to wear it."

All 6’3" of Christie covered in mirrored metal might have caused some reflection headaches for the cinematographer, but "That's not my responsibility," Kaplan chuckles. "She looked wonderful."